Proposed Precast Plant

Maxxing Out a Mixer

Manufacture of the product is based on providing a steady, consistent flow of self consolidating concrete to fill hundreds of precision molds for wall panels of unrivaled efficacy.
The system is designed to withstand virtually anything, including E5 tornados. There are many options as to how extra strength is applied to the system.
The first premise is a continuous flow of concrete of 6 pounds per second. That will entail 6-1/2 seconds per the standard 38 pound 24" x 16" panel mold. So over the course of a nine hour day, 8 plus lunch plus breaks, 6 pounds per second x 60 seconds per minute x 60 minutes per hour x 9 hours = 194,400 pounds of concrete. At 4,000 pounds per yard of concrete = 48.6 yards of concrete. The average mold weight is 38 pounds so approximately 5,115 molds are needed.
The average panel area is 14.7 pounds per square foot. So 194,400 pounds of concrete will make (divided by 14.7) 13,224 square feet of panel.
An approximate rule of thumb is that each square foot of house floor plan square footage will take approximately 3.3 square feet of panel. If special ceiling forming pavers are used for elevated slabs then the number goes to 4.3.
Assume a house of 2,000 square feet. About 8,600 square feet of panel would be used. So 13,224/8,600 = 1.54 houses per day supplied.
At two shifts per day, 3 hours between shifts, 3 houses supplied per day.
Quadruple the panel square footage for manufacturing square footage. That requires about 53,000 square feet. 53.000 square root = a facility 230 feet square.
Propose 12' high ceiling plus roof thickness, 10 panels high, perimeter = 920 feet, 9,200 sq ft wall, inside and out panels 18,400 sq ft.
Palletizing panels, 2,000 pounds per pallet. Let panels cure 2 weeks before delivery.
Outside storage (yard space) Two weeks of panels, two shifts per day = 194,400 x 2 shifts x 6 days per week x 2 weeks divided by 2,000 pounds per pallet, 4' x 4' = 16 sqft per pallet, 2,333 pallets
2,333 x 16 sq ft = 37,328 square feet of pallets, give 50% spacing = 56,000 sq ft of pallet storage space.
Have that take 1/3 of yard to allow for trucks etc
Net yard space required = 168,000 sq ft
Add manufacturing plant + 53,000 = 221,000 sq ft lot needed
43,560 sq ft per acre, need a 5 acre site
221000/ 300 = 300 x 740 feet space or 470 feet square
Five fully loaded flat bed trucks leaving with product per day, can build 8 houses approximately

Labor

On average, conservatively looking at it, say 20 minutes per mold for all operations

5,115 molds used, = 1,705 hours, 7 hours per worker, 244 person labor force

244 workers x 8 hours per day x $35/hour = $68,320 per day

5 shifts per week = $341,600 per week

November, December, January Off

40 weeks per year = $13,664,000 per year payroll

Sales

13,224 square feet of panel per shift
Six or 12 shifts per week, go with six now, 79,344 square feet of panel per week
Sales price per square foot = $12
$952,128 revenue per week
Panels converted into sold houses 25% margin per house,

Materials Cost

50 yards of concrete @ $200 per yard = $10,000
One expanded steel per 1.33 sq ft of panel = 13,224 sq ft / 1.33 = 9,943 pieces
144 pieces per sheet, 69 sheets, @$80 sheet = $5,524
Polystyrene inserts into half (open voids the other half of panels) of panels will be two for every expanded steel = 19,946 pieces, 4"x12", 96 per sheet, 208 sheets, $22 each, $4,576
Plastol 6400, 84 ounces per yard of concrete, times 50 yards, = 3,440 ounces, = 27 gallons, $40/gallon, = $1,080
3" polyiso sheets, $50 per sheet, half of panel area, 6,612 square feet, /32 sf per sheet, 207 sheets, $10,350, at 3" thickness = 621" = 52' stack, so 9 six feet high stacks taking up 288 sq feet, 340 sq ft for handling.

Total sales and cost

Sales = 13224 x $12 = $158,688

Total materials cost = $31,530

Labor plus materials = $99,850

Seek 100% Margin, $200,000 sales revenue, Sell for $15.13 per square foot

Specific price per panel apportioned per degree of difficulty

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